Integrated solenoid coil and rectifier assembly



May 21, 1968 s. H. SCHWARTZ INTEGRATED SOLENOID COIL AND RECTIFIERASSEMBLY Filed July 1 5, 1965 INVENTOR. kwuzz Saw/14427.2

m N w W A United States Patent 3,384,787 INTEGRATED SOLENOID COIL ANDRECTIFIER ASSEMBLY Samuel H. Schwartz, Morton Grove, Ill., assignor toThe Dole Valve Company, Morton Grove, Ill., a corporation of IllinoisFiled July 15, 1965, Ser. No. 472,238 Claims. (Cl. 317123) ABSTRACT OFTHE DISCLOSURE A selenium plate rectifier in series connection with asolenoid coil which is wound around a bobbin, and encapsulating meanswhich enclose the rectifier integrally with the bobbin and coil.

The present invention relates to solenoid constructions and moreparticularly to an integrated alternating current solenoid coil andrectifying circuit construction.

It has been found desirable in many instances to provide solenoidconstructions with a means for supplying their respective coils withdirect current from an alternating current (AC) supply line. Sucharrangements insure smoother and quieter operation and the use of directcurrent (DC) energized coils is well-known to those skilled in this art.The usual manner of accomplishing DC coil operation is to provide aseparate alternating current rectifying circuit which operates off analternating current supply line and which provides the required directcurrent to the solenoid coil.

Such arrangements may prove entirely satisfactory insofar as operatingability is concerned but devices which must be connected to separatealternating current rectifying circuits or to independent DC supplylines are cumbersome and not practical in use. Solenoid assembliesconstructed in accordance with the principles of the present inventionhave an alternating current rectifying unit disposed within a moldedpocket in a solenoid coil bobbin. With such an arrangement, potting orencapsulation of the coil will envelop the rectifying unit right alongwith the coil itself to protect the rectifying unit and provide an endproduct which is small, efficient, and tamper-proof.

It is therefore a principal object of the present invention to provide asolenoid coil construction wherein an AC rectifying unit is connected toand forms an integral part of a solenoid coil assembly itself.

A still further and more specific object of the invention resides in theprovision of a solenoid coil assembly of the type described abovewherein an AC rectifying unit is fitted within a molded pocket formed inthe end flange of a solenoid coil bobbin intermediate the terminalsprotruding therefrom.

These and other objects, features and advantages of the presentinvention will become apparent from time to time as the followingspecification proceeds and with reference to the accompanying drawings,wherein:

FIGURE 1 is a perspective view partly cut away illustrating an integralsolenoid coil and rectifier construction according to the principles ofthe present invention;

FIGURE 2 is a perspective view illustrating the construction of FIGURE 1in an integrated, encapsulated form according to the invention.

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This invention contemplates the formation of an integrally constructedsolenoid coil and rectifier unit and wherein the entire unit isencapsulated with only the input terminals to the unit being exposed andrequired to be connected to an AC power supply line for operating thesolenoid coil with direct current.

In FIGURE 1 there is illustrated a bobbin 10 which is formed of anelastomeric material such as nylon. The bobbin 10 is molded in the usualmanner for use with solenoids and includes a bobbin comprising a hollowtubular portion 11 and a pair of end flanges 12 and 13 at respectiveends of the tubular portion 11.

The end flange 13 includes protrusions 14 and 15 each having respectiveentrances 16 and 17 to accommodate a pair of terminals 18 and 19 whichare formed of a conductive metal and serve as AC power supply line inputterminals. Each of the terminals 18 and 19 has a small lip or grippingfinger at one end thereof so that it is held within the bobbin 10 bypushing the respective terminal into its protrusion with the lip orfingers engaging the bobbin within the protrusion to securely mountthereto.

A coil 20 of thin wire is wound in overlapping layers on the tubularportion 11, with one lead end 21 of the coil 20 being wrapped around theterminal 18 preparatory to making the usual solder electrical connectionthereto.

In between the protrusions 14 and 15, and immediately adjacent the endflange 13, there has been provided a frame 22 forming a pocket whichaccommodates a stack of selenium rectifier plates 23. Obviously, withsuch an arrangement the entire rectifier unit can be encapsulated withan insulating plastic covering right along with the coil and bobbin. Theframe 22 is formed of a relatively thin, preferably resilient materialintegral with the bobbin. The frame 22 includes two Y-shaped portions 24and 25 at each end thereof having their tails formed integrally with theprotrusions 14, 15 and interconnected by a top and bottom fiat portion26. The rectifier stack 23 is constructed of the required number ofselenium plates to provide the voltage rating necessary for the coil 20.The frame 22 is formed such that the distance between the top portion26a and the bottom flat portion 26b, in the unstressed condition of theframe, is just slightly less than the height of the rectifier stack 23.

The Y-shaped portions 24 and 25 provide the necessary supportingstructure for the plates between the protrusions 14 and 15, and alsoprovide a slight amount of resiliency between top flat portion 26a andbottom portion 2612. Thus when the stack of rectifier plates 23 isinserted into the frame 22, the flat portions 26a and 26b are urgedslightly apart to accommodate the plates, and upon full insertion of thestack 23 within the frame 22 the Y- shaped portions 24 and 25 operate onthe portions 26a and 26b to resiliently but firmly maintain the stacktherebetween. A pair of rectifier terminals 27 and 28 are provided andproject slightly beyond a front edge 29 of the frame 22 so thatelectrical connections can be made between the plates 23, the coil 20and the terminals 18 and 19.

A second coil lead 30 which is the other end of the coil 20 with respectto the lead 21, is mechanically and finally electrically connected tothe rectifier lead 27. It may also be noted from FIGURE 1 that the ACterminal 19 is electrically connected to the rectifier terminal 28 bymeans of a r wire 31. Thus, electrically the rectifier plates 23 and thecoil 20 are connected in series with an AC power supply line so that theinput alternating current supply is rectified by the plates 23 in theusual and well-known manner to provide a rectified direct current tooperate the solenoid coil 20.

Referring now to FIGURE 2, there is shown the completed integral coiland rectifier construction according to the principles of the presentinvention. It may be particularly noted that the unit shown in FIGURE 2includes the bobbin 10, with the coil 20 wound thereon, the rectifierplates 23 held within the frame 22 and the terminals 18 and 19. Theconstructed unit as shown in FIGURE 1 is then encapsulated withencapsulating material similar to that forming the bobbin and the frameto provide the completed and encapsulated coil and rectifier 34 as shownin FIGURE 2. Encapsulation protects the entire unit from shock and frompossibly corrosive or destructive foreign materials.

The encapsulating material 33 is formed completely around the rectifierstack 23, the frame 22, the coil 20 and the bobbin 10, so that only theAC input terminals 18 and 19 protrude from the assembly. Theinterconnections between the rectifier plates 23 and the coil 20 have ofcourse been encapsulated so that they lie wholly within the material 33.Thus, there has been provided a compact integral rectifier and coilconstruction such that direct current operation of the coil is effectedin an efficient manner.

As an illustration of the compactness of such a unit as is illustratedin the drawings which embodies the principles of the present invention,the frame 22 accommodates selenium plates which are approximatelysquare. Also, the space betwen the top flat portion 26a and the bottomflat portion 26b is such that for operation of a 120 volt AC coil 8 to10 plates, each being approximately 0.030" thick, will fit therebetween.

Other means might be employed to hold the rectifier stack in positionuntil the entire unit is encapsulated, in accordance with the principlesof the invention. For instance, the bobbin 10 could be formed with onlythe tubular portion 11, and the end flanges 12 and 13. The terminals 18and 19 could then be press-fitted into the end fiange 13 in a similarmanner as described previously. A separate frame structure includingportions substantially similar to the frame 22 and the associatedportions of protrusions 14 and 15 might be slipped onto the terminal 18and 19. The coil could then be wound on the tubular portion 11, therectifier stack inserted into the frame, the series connection madebetween the rectifiers and the coil, and finally the entire unitencapsulated to derive a unit similar in appearance to that shown inFIGURE 2.

Also, in the cut away perspective view of FIGURE 1 there has been shownmerely for illustrative purposes a half-wave rectifier formed by therectifier plates 23. Similar arrangements could be provided if it weredesired that a full-wave, or other types of rectifier circuits beencapsulated with the coil in an assembly as shown in FIGURES l and 2.

Although the drawings and specification present a detailed disclosure ofa preferred embodiment of the present invention, it is to be understoodthat the invention is not limited to the specific form disclosed, butcovers all modifications, changes and alternative constructions fallingwithin the scope of the principles taught by the invention.

I claim as my invention:

1. An integrated coil and rectifier circuit comprising:

a bobbin for supporting said integrated circuit,

a coil of thin wire wound in overlapping layers on said bobbin,

a plurality of selenium plates forming a rectifier circuit and seriallyconnected to said coil, and

a frame on said bobbin in resilient engagement with said plates andmaintaining said plates therewithin.

2. An integrated coil and rectifier circuit for operating from an ACsupply line comprising:

a bobbin for supporting said integrated circuit,

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a coil of thin wire wound in overlapping layers on said bobbin,

a frame integral with said bobbin including a chamber having at leasttwo sides resiliently formed with respect to each other, and

a plurality of selenium plates interconnected to form a half-waverectifier circuit and serially connected to said coil,

said plates resiliently maintained within said chamber to enable saidcoil to operate with rectified alternating current supplied from saidsupply line via said rectifier circuit.

3. An integrated coil and rectifier circuit comprising:

a bobbin for supporting said coil and rectifier circuit,

a coil of wire wound in overlapping layers on said bobbin,

a rectifier circuit on said bobbin serially connected to said coil; and

means including encapsulating material for enclosing said coil andrectifier circuit coextensively with said bobbin.

4. An integrated AC solenoid coil and rectifier circuit comprising:

a bobbin including an end flange and a hollow tubular member,

a coil of thin wire Wound in overlapping layers on said tubular member,

a frame adjacent said end flanges,

a plurality of selenium rectifier plates held within said frame, saidrectifier plates coupled to form a halfwave rectifier circuit seriallyconnected to said coil, and

means including encapsulating material for enclosing said coil, saidrectifier plates held within said frame coextensively with said bobbin.

I 5. In an alternating current solenoid coil assembly including a bobbinand a coil wound thereon, the improvement comprising:

a selenium rectifier circuit for supplying rectified current to saidsolenoid coil, and

means integral with said bobbin for compactly mounting said rectifiercircuit within said assembly.

6. In an alternating current solenoid coil assembly including a bobbinand a coil wound thereon, the improvement comprising:

a selenium plate rectifier circuit in series connection with saidsolenoid coil for supplying rectified current thereto,

a frame on said bobbin for resiliently supporting said rectifier circuitin close operating position to said coil on said bobbin, and

encapsulating means enclosing said frame and rectifier circuitintegrally with said bobbin and coil.

7. A solenoid coil assembly comprising:

a bobbin formed of electrically nonconductive material and having atubular winding portion and end flanges formed on opposite ends of saidwinding portion,

a pocket formed in one of said end flanges, an alternating currentrectifier assembly carried within said pocket,

a coil wound on said winding portion, and

means connecting said rectifier assembly in series with said coil.

8. A solenoid coil assembly constructed in accordance with claim 7wherein said assembly is completely encapsulated in an imperviouselectrically insulating material and wherein terminals are connected inseries with said coil and rectifier assembly and protrude from theencapsulated coil assembly.

9. A solenoid coil assembly comprising:

a bobbin formed of electrically nonconductive material and having atubular winding portion,

one of said end flanges having spaced apart walls cooperating to definea pocket,

an alternating current rectifier assembly carried within said pocket,

a coil wound on said winding portion,

means connecting said rectifier assembly in series with said coil,

and wherein said spaced apart walls are formed of resilient material andare spaced apart a distance in their unstressed condition somewhat lessthan one dimension of said rectifier assembly,

whereby the resiliency of said spaced apart walls will grip andpositively maintain said rectifier assembly in a fixed position withinsaid pocket.

10. A solenoid coil assembly constructed in accordance with claim 9wherein said assembly is completely encapsulated in an imperviouselectrically insulating material and wherein terminals are connected inseries with said coil and rectifier assembly and protrude from theencapsulated coil assembly.

No references cited.

MILTON O. HIRSHFIELD, Primary Examiner.

J. A. SILVERMAN, Assistant Examiner.

